Product package and system

ABSTRACT

A product package system is provided comprising a blister pack having a cavity and an overwrap. The system enables a product to be packaged and easily removed by opening the overwrap. The overwrap can include tear strips to facilitate easy opening. The blister pack can embody a clamshell pack having a living hinge.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a national phase application under 35 U.S.C. §371 of PCT Application No. PCT/US2010/056022 filed Nov. 9, 2010, which claims the benefit of U.S. Provisional Application No. 61/259,467, filed Nov. 9, 2009, the contents of each of which are expressly incorporated herein by reference.

FIELD OF ART

Product packages for consumer goods, such as blister packs for toys, glasses, consumer electronics, videos, games, etc., are generally discussed herein with particular discussions on blister packs having easy to remove security overwrap covers.

BACKGROUND

Prior art blister packs for packaging toys and consumer components, such as electronics, toys, and accessories, among others, are typically heat sealed for shipping, displaying, and providing security. They have a clam-shell configuration made from a thermoforming process in which one-half of the clamshell is formed with a cavity and the other half either as a flat lidding or with a second cavity to increase the overall cavity dimension of the clam-shell. The two sections are typically sealed along a common perimeter, using frequency sealing, ultrasonic sealing, or simple heat seal. An optional paper insert may be provided for art work and other ad space, such as product information and product name.

Although prior art blister packs serve their intended needs, they pose issues for consumers and the environment. Among other things, blister packs are made of durable plastics, such as polyvinyl chloride (PVC), which make them hard to open. Among small circles of consumers, the difficult-to-open packages have given rise to “wrap rage”. Furthermore, the all plastic configuration goes against recent environmental push for plastic reduction to reduce carbon footprint.

Accordingly, there is a need for a better or at least an alternative package usable for various applications, such as consumers, aerospace, medical, and energy.

SUMMARY

The present apparatus, device, and method may be practiced by providing a product package system comprising a blister pack. The blister pack can comprise a cavity placed inside an overwrap comprising an opening; wherein the cavity projects, at least in part, out the opening of the overwrap; and wherein a flap on the overwrap is folded over a package opening and is fixed to a surface near the package opening by adhesive.

In yet another aspect of the present apparatus, device, and method, there is provided a method for assembling a product package system comprising placing a consumer product into a cavity of a blister pack; placing a lidding against the blister pack so as to cover the cavity; placing the blister pack and lidding into a package opening of an overwrap; aligning the cavity so that the cavity projects outwardly of at least one window incorporated in the overwrap; and applying an adhesive to close the packaging opening.

In still yet aspect of the present method is a method for using a product package system. The method of using the product package system comprising causing a side of an overwrap of the product package to open to expose an interior cavity of the overwrap. The method further comprising the steps of extracting a blister pack from the interior cavity of the overwrap and separating a cover on the blister pack to expose a cavity on the blister pack without cutting the cover or the blister pack. Finally, the method includes the step of extracting a product from the cavity of the blister pack.

Other aspects and variations of the glove assemblies summarized above are also contemplated and will be more fully understood when considered with respect to the following disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present apparatus, system, and method will become appreciated as the same become better understood with reference to the specification, claims and appended drawings wherein:

FIG. 1 is an exemplary semi-schematic perspective view of a lidding of a blister pack provided in accordance with aspects of the present disclosure,

FIG. 2 is an exemplary perspective view of a blister pack provided in accordance with aspects of the present disclosure,

FIG. 2A is an exploded top view of an upper left corner of the blister pack of FIG. 2;

FIG. 3 is an exemplary perspective view of a blister pack assembly provided in accordance with aspects of the present disclosure;

FIG. 4 is an exemplary schematic perspective view of an overwrap configured for receiving the blister pack assembly of FIG. 3 provided in accordance with aspects of the present disclosure;

FIG. 5 is an exemplary perspective view of a product package system provided in accordance with aspects of the present disclosure;

FIG. 6 is an exemplary front view of the product package system of FIG. 5; and

FIG. 7 is an exemplary rear view of the product package system of FIG. 5.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of product packages and systems (herein “package or package assembly”) provided in accordance with aspects of the present disclosure and is not intended to represent the only forms in which the present disclosure may be constructed or utilized. The description sets forth the features and the steps for constructing and using the package assembly of the present disclosure in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the disclosure. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.

FIG. 1 is a schematic view of a lidding 10 provided in accordance with aspects of one embodiment. The lidding 10 has a first surface 12, an opposed second surface 14, a length L and a width W. The lidding 10 can be made from any suitable natural, synthetic, composite, and laminate materials, including but not limited to paper and board materials; metals and foils; or plastics. In a preferred embodiment, the lidding 10 is made from a paperboard material. In one embodiment, the lidding 10 may be made from a prior art material having acceptable thickness or weight, including from paperboard material and from recyclable material. The first surface 12, the second surface 14, or both may have printing or art work, such as for describing the contents of the package and/or for providing manufacturer information, among others.

FIG. 2 is a schematic view of a blister pack 16 provided in accordance with aspects of one embodiment. The blister pack 16 may be made from a transparent or opaque plastic or other rigid or semi-rigid materials. The blister pack 16 can be made from any suitable natural, synthetic, composite, and laminate materials, including, without limitation, plastics such as cellulose acetate butyrate (CAB), polystyrene, polyethylene terephthalate (PETG); polycarbonate; polyethylene, including PET, PVC, HDPE, and LDPE; polytetrafloralethylene; acetal, acrylic and combinations thereof.

In some embodiments, the blister pack 16 may be made from a thermoforming process using suitable plastic materials, such as from PET or PVC or other known plastics for thermoforming a blister pack for packaging consumer goods. The plastic material is preferably transparent. However, an opaque or a semi-opaque material may be used without deviating from the spirit and scope of the present disclosure. In another embodiment, the blister pack 16 is made from a vacuum forming process. In yet other embodiments, the blister pack 16 may be formed by injection molding. In alternative embodiments, the blister pack 16 may be formed by other suitable plastic manufacturing processes, including but not limited to blow molding or rotational molding.

As shown in FIG. 2, the blister pack 16 comprises a cavity 18 having a defined volumetric capacity. The cavity 18 can have a rectangular, a square, a cylindrical or any other appropriately shaped container configuration for storing consumer goods with rectangular and square configurations being more preferred. For example, the cavity can have an irregular shape for accommodating an irregular shaped toy.

In other embodiments, the cavity 18 is made of several individual cavities. The individual cavities can have different configurations, including but not limited to irregular shape, rectangular shape, square, cylindrical, elliptical or combinations thereof. In some embodiments, the individual cavities are separately formed and assembled into the cavity 18 to form multiple sub-cavities. In one embodiment, the separately formed individual cavities are stacked vertically one on top of another, horizontally one adjacent to another, or combinations thereof. In alternative embodiments, the individual cavities are created by dividing the space within the cavity 18 using, for example, panels or partitions. In some embodiments, the individual cavities are identically sized and shaped. In alternative embodiments, the individual cavities are configured for housing objects of varying sizes and shapes. In some embodiments, the cavity 18 comprises multiple individual cavities, such as cavities 18 a, 18 b. and 18 c for separately housing glasses. In alternatives embodiments, the cavity 18 may comprise a plurality of individual cavities, such as two to ten, or more than ten, configured for housing different consumer goods.

The cavity 18 is positioned on the blister pack 16 such that a first gap or distance D1 is formed between the upper edge of the blister pack and the upper sidewall surface of the cavity 18; a second gap or distance D2 is formed between the lower edge of the blister pack 16 and the lower sidewall surface of the cavity 18; and two side gaps or distances D3 and D4 are formed between the side edges of the blister pack 16 and the left and right sidewalls of the cavity 18, respectively. In one example, D1 equals to D2 and D3 equals to D4. In other embodiments. D1 equals to D2, which is equal to D3, and which is equal to D4. In another example, D1 is not equal to D2. As further discussed below, the gaps D1-D4 are sized so that the cavity 18 can project out of a window of an overwrap and fits securely and snugly within the window of the overwrap, as further discussed below. Because of the location of the cavity 18 and relative dimensions of the cavity and the window of the overwrap, the blister pack 16 cannot be removed from the overwrap without tempering with the overwrap, such as by cutting the window or opening the tear strip.

The blister pack 16 comprises two or more spaced apart channels 20 configured to receive the lidding 10 of FIG. 1. The channels 20 may be formed by folding the left and right edges of the material used to make the blister pack 16. FIG. 2A is an exploded view of an upper left corner of the blister pack 16 of FIG. 2 showing one of the two or more receiving channels 20.

Thus, aspect of the present apparatus, assembly, and method is understood to include a blister pack comprising a cavity for receiving a consumer product, such as a toy, an accessory, an electronic component, cards, a video chip, a DVD, etc., and two spaced apart channels configured for receiving a lidding. In one specific example, the two spaced apart channels are formed by folding two edges of a body of material for forming the blister pack. In another example, the folds are formed along a longer dimension of the body but can be formed along the shorter dimension of the body. If the body of material for forming the blister pack is generally rectangular, then the folds may be formed along any two spaced-apart edges.

FIG. 3 is a schematic view of a blister pack assembly 22, which comprises the lidding 10 of FIG. 1, the blister pack 16 of FIG. 2, and one or more consumer products (not shown) placed in the cavity 18 of the blister pack. In practice, after the cavity 18 is occupied with one or more consumer products, the lidding 10 is slid into the two spaced apart channels 20 to form the blister pack assembly 22. In some embodiments, the lidding 10 is held within the two receiving channels 20 by friction or by a third channel formed along the lower width section of the blister pack 16 (not shown) between the two spaced apart channels 20. In alternative embodiments, the lidding 10 may be retained within the two receiving channels 20 by a retainer means, such as a latch, fastener or the like. Alternatively or in addition thereto, the lidding 10 may be secured to the blister pack 16 using staples, tapes or combinations thereof. For example, the lidding may be placed against the blister pack and stapled thereto without the channels 20, although the channels may also be incorporated. In still another example, the lidding and the blister pack may incorporate corresponding snap-fit engagement means, such as detents, tongue and groove, etc. In this example, the lidding may be made from similar material as the blister pack.

Thus, aspect of the present embodiment is understood to include a method for forming a blister pack assembly, comprising providing a blister pack comprising a cavity for receiving one or more consumer product, and two or more spaced apart channels configured for receiving a lidding; placing the one or more consumer product within the cavity; and engaging the lidding into the two or more spaced apart channels to close the blister pack.

In an alternative embodiment, a clamshell having a foldable hinge and one or more cavities may be used instead of the disclosed blister pack 16. If the alternative clamshell is used, then the lidding may be omitted. However, the common edges of the clamshell does not have to be heat sealed before placing the clamshell into an overwrap. Leaving the two sections merely touching or using a simple snap-fit arrangement or staples are possible options.

FIG. 4 is a schematic view of an overwrap 24 provided in accordance with aspects of the present apparatus, assembly, and method. In one embodiment, the overwrap 24 is made from a chip board, a fiberboard, a film, TYVEK® synthetic material (e.g., high-density polyethylene fibers), a multi-laminate film, other suitable materials, or combinations thereof. The overwrap is preferably made from a difficult to tear or temper material. The overwrap 24 has a front layer 32, a back layer 34, which are attached to one another along one or more common peripheral edge, and a package opening 36 that opens up into an interior cavity of the overwrap. In some embodiments, the overwrap 24 comprises an adhesive closure system 26 for closing the package opening 36 after a product has been placed inside. In other embodiments, the package opening 36 may be closed using staples, tapes or combinations thereof. In some embodiments, the opening 36 is sized to receive the blister pack and the overwrap 24 is sized to accommodate the blister pack 16 with the cavity 18 projecting out of the window 30. In a specific embodiment, the overwrap 24 embodies a similar configuration as a mailer, such as an Express Mail envelope from the US Postal Office or a FedEx envelope. In another embodiment, the overwrap has a tear strip 28 for removing the blister pack and the contents. In one embodiment, the adhesive closure system 26 and tear strip 28, when both are incorporated, are located along one lengthwise edge of the overwrap 24. In another embodiment, the adhesive closure system and tear strip are located along one widthwise edge of the overwrap. The overwrap can be viewed broadly as having an opening and a mechanism for closing the opening after the blister pack has been placed therein. In still other embodiments, the adhesive closure system and tear strip are located along two or more edges of the overwrap, such as along the two lengthwise edges or along one lengthwise edge and one widthwise edge. The overwrap 24 may have printing or indicia identified thereon, such as a logo, product information, product code, bar code, instructions, etc., for facilitating sales and marketing.

As shown, an opening or window 30 is incorporated on the front layer 32. The window may be die cut to size before securing the front layer 32 to the back layer 34. For example, the window may be cut with a size sufficient to accommodate the cavity 18 of the blister pack assembly 22 and allow the cavity 18 to project outwardly therefrom, as further discussed below. In an alternative embodiment, a second window (not shown) is incorporated on the second layer 34 of the overwrap for accommodating a two-cavity clamshell blister pack. In another example, the window 30 is formed with ribs or spacers so as to form multiple windows for separately accommodating the different cavities on a multi-cavity blister pack, such as that shown in FIG. 3.

In still yet another embodiment, pleats may be incorporated along one or more of the edges of the overwrap 24, such as along all the edges of the overwrap. The pleats (not shown), when incorporated, allow the package opening 36 to be opened sufficiently wider than a comparable overwrap without pleats to receive the blister pack assembly 22, as further discussed below. Also although not shown, a hanging bore or opening (not shown) may be incorporated for hanging the overwrap on a hook for displaying, such as on a store shelf.

FIG. 5 is a schematic view of a product package system 38 of the present embodiment. The system 38 is formed by placing the blister pack assembly 22 of FIG. 3 through the package opening 36 of the overwrap 24 of FIG. 4 and aligning the two so that the cavity 18 projects out the window 30. The gaps D1, D2, D3 and D4 surrounding the cavity 18 (FIGS. 2 and 3) are thus retained within the upper wall, the lower wall and the two side walls around the window 30, respectively. The corresponding surfaces of the overwrap and the blister back secure the blister pack assembly 22 within the overwrap 24. As configured, the blister pack assembly 22 cannot be removed from the overwrap 24 without tempering with the overwrap, such as by cutting the window 30 or opening the tear strip 28. Among other things, once the closure system is closed, the size of the blister pack assembly 22 is physically too large for the only remaining opening 30 to extract the blister pack. Where multiple windows are provided, alignment is required to place each rib between each adjacent sub-cavity, such as between cavities 18 a and 18 b. The closure system 26 is then used to enclose the blister pack assembly 22 within the overwrap 24.

FIGS. 6 and 7 are front and rear views of the product package system 38 of FIG. 5, respectively. The blister pack assembly 22 may be removed from the overwrap 24 by pulling on the tear strip 28 to open the package opening 36 and remove the blister pack assembly 22. Once removed, the blister pack assembly 22 can be fully opened by separating the lidding 10 from the blister pack 16. The lidding 10 can easily be separated from the blister pack 16 by sliding the lidding 10 out of the receiving channels 20. As described, the consumer product placed within the cavity 18 of the blister pack assembly 22 is accessible without having to cut open the blister pack assembly 22. Furthermore, the ability to fully open the blister pack assembly 22 and to completely remove the lidding 10 from the blister pack 16 facilitates recycling of the various components of the blister pack assembly 22 in that paper and plastic components can easily be sorted and placed in appropriate recycling bins.

As understood, an aspect of the present disclosure is a product package system comprising a thermoformed blister pack placed inside an overwrap comprising an adhesive closure system. In another embodiment, a tear strip is provided on the overwrap for removing the blister pack.

The present disclosure is further understood to include a lidding for sliding between two spaced apart channels formed on the blister pack before placing the blister pack into the overwrap. In a specific embodiment, a cavity on the blister pack projects out a window incorporated on a front layer, a back layer, or both layers of the overwrap.

A still further feature of the present disclosure is a method for making a product package system comprising a clamshell blister pack and for assembling one or more consumer products within the clamshell blister pack without having to heat seal the clamshell blister pack. By not heat sealing the clamshell blister pack, the product package system is less costly and less labor intensive to produce due to the fewer steps. Furthermore, the product package system is easier to package and open. Still furthermore, recycling is made easier due to the ability to fully open the blister pack and sort between plastic and paper.

Although limited embodiments of the product package system and its components have been specifically described and illustrated herein, many modifications and variations will be apparent to those skilled in the art. For example, the various components may be made from different materials, different art may be used for product placement and information, such as incorporating different colors, and different sizes may be used for packaging different contents. Furthermore, it is understood and contemplated that features specifically discussed for one package and system may be adopted for inclusion with another provided the functions are compatible. Accordingly, it is to be understood that the illustrated embodiments have been set forth only for the purposes of examples, and that the embodiments should not be taken as limiting the disclosure as defined by the following claims. The following claims are, therefore, to be read to include not only the combination of elements which are literally set forth, but all equivalent elements for performing substantially the same function in substantially the same way to obtain substantially the same result. The claims are thus to be understood to include those that have been illustrated and described above, those that are conceptually equivalent, and those that incorporate the ideas of the present disclosure. 

What is claimed is:
 1. A product package system comprising a blister pack comprising a cavity placed inside an overwrap comprising an opening; wherein the cavity projects, at least in part, out the opening of the overwrap; and wherein a flap on the overwrap is folded over a package opening and is fixed to a surface near the package opening by adhesive.
 2. The product package system of claim 1, wherein the blister pack comprises two spaced apart channels.
 3. The product package system of claim 2, wherein a lidding is positioned between the two spaced apart channels.
 4. The product package system of claim 3, wherein the lidding is slidable relative to the blister pack.
 5. The product package system of claim 1, wherein the overwrap further comprises a tear strip.
 6. The product package of claim 1, wherein the cavity comprises a plurality of sub-cavities.
 7. The product package of claim 3, wherein the lidding is made of a paperboard material.
 8. The product package of claim 1, wherein the blister pack further comprises a second cavity, the second cavity projects out a second opening on the overwrap.
 9. The product package of claim 1, wherein the blister pack is made of a thermoplastic material.
 10. The product package of claim 1, wherein the overwrap comprises pleats configured for expanding.
 11. A method for assembling a product package system comprising: placing a product into a cavity of a blister pack; placing a lidding against the blister pack so as to cover the cavity; placing the blister pack and lidding into a package opening of an overwrap; aligning the cavity so that the cavity projects outwardly of at least one window incorporated in the overwrap; and applying an adhesive to close the packaging opening.
 12. The method of claim 11, wherein the lidding engages a channel on the blister pack.
 13. The method of claim 11, wherein the blister pack comprises two spaced apart channels configured for receiving the lidding.
 14. The method of claim 11, wherein the overwrap comprises a tear strip.
 15. The method of claim 11, wherein the cavity comprises a plurality of compartments.
 16. The method of claim 11, wherein the lidding is made of a paperboard material.
 17. The method of claim 11, wherein the blister pack is made from a transparent material.
 18. The method of claim 11, wherein the blister pack is made of a thermoplastic material.
 19. The method of claim 11, wherein the overwrap comprises pleats along at least one edge of the overwrap.
 20. A method for using a product package system comprising: causing a side of an overwrap of the product package to open to expose an interior cavity of the overwrap; extracting a blister pack from the interior cavity of the overwrap; separating a cover on the blister pack to expose a cavity on the blister pack without cutting the cover or the blister pack; and extracting a product from the cavity of the blister pack. 